Channel Drain With Integral Weep Path

ABSTRACT

A channel drain assembly includes a channel drain and a grate. The channel drain includes a body having at least one sidewall and a bottom wall, a flange extending about a periphery of the body, and a drain pipe. The grate is positionable within the body and includes at least one side wall and a top wall that has a plurality of apertures extending therethrough. When the grate is positioned within the body a first flow path and a second flow path are formed that provide a path for fluid to flow into the channel drain and out the drain pipe. The first flow path is formed across the plurality of apertures, while the second flow path is formed between the at least one side wall of the grate and at least one sidewall of the body.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to channel drains, and, more specifically, to a channel drain having an integral weep path and a method of installing a channel drain having an integral weep path.

2. Related Art

Floor drains, including channel drains generally, are well known in the art. Floor drains could be installed through the flooring of a room to allow water to flow along the floor and exit through the drain. In some instances the floor could include a separate housing that the floor drain is installed through, e.g., a bathtub or a residential shower enclosure, while in other embodiments the floor drain could be installed directly in the floor with a tile or ceramic layer flush with the drain. Regardless, in both instances a sub-drain must be installed along with the floor drain, creating a weep path for excess fluid to flow along and to an exit pipe.

FIG. 1 is a cross-sectional view of an exemplary prior art floor drain that includes a sub-drain. The floor drain assembly 10 includes a channel drain 12 connected to a first drain pipe 14 and a sub-drain 16. The sub-drain 16 is installed in a subfloor 18. A backerboard 20 is installed on top of the subfloor 18 and over the sub-drain 16, and a waterproof membrane 22 is installed over the backerboard 20. The channel drain 12 is installed over the waterproof membrane 22 and the sub-drain 16, such that water drains through the channel drain 12, the connected first drain pipe 14, and into the sub-drain 16, e.g., in the direction of arrows A. The channel drain 12 is secured with the sub-drain 16 by a clamping flange 24 and a sub-drain seal 26. The clamping flange 24 and the sub-drain seal 26 are positioned between the first drain pipe 14 of the channel drain 12 and the waterproof membrane 22 and the backerboard 20. This arrangement creates two different fluid flow paths. First, the floor drain assembly 10 allows fluid to flow through the channel drain in the direction of arrows A and into the sub-drain 16 without contacting the waterproof membrane 22. Second, the floor drain assembly 10 allows fluid that does not reach the channel drain to flow under the channel drain along arrows B (known as a weep path) and into the sub-drain 16. As shown, both fluid flows A and B flow to the sub-drain 16 and through the second drain pipe 28 connected to the sub-drain 16, and to the sewer system.

The floor drain assembly 10 of the prior art requires a sub-drain to be installed separate from, and in addition to, a channel drain. Accordingly, what would be desirable, but has not yet been provided, is a system and method of installing a floor drain that addresses the foregoing limitations of existing floor drains.

SUMMARY OF THE INVENTION

The present invention relates to a channel drain assembly including a channel drain and a grate. The channel drain includes a body having at least one sidewall and a bottom wall, a flange extending about a periphery of the body, and a drain pipe. The grate is positionable within the body and includes at least one side wall and a top wall that has a plurality of apertures extending therethrough. When the grate is positioned within the body a first flow path and a second flow path are formed that provide a path for fluid to flow into the channel drain and out the drain pipe. The first flow path is formed across the plurality of apertures, while the second flow path is formed between the at least one side wall of the grate and at least one sidewall of the body.

In one embodiment, the drain pipe extends from the bottom wall of the channel drain body. In another embodiment, the channel drain also includes a basin extending from the bottom wall of the body, and the drain pipe extends from a side of the basin.

The present invention further relates to a method of installing a channel drain assembly. A channel drain is provided that has a body, a flange extending about a periphery of the body, and a drain pipe. A grate is also provided that is positionable within the body and includes at least one side wall and a top wall, the top wall having a plurality of apertures extending therethrough. A location for installation of the drain pipe is determined and a subfloor is installed at the installation location. A backerboard is then installed on top of the subfloor. A hole dimensioned slightly larger than the dimensions of the channel drain body is cut through the subfloor and the backboard. The channel drain body is then placed into the hole such that the flange rests on the backerboard. Next, a hole dimensioned to match the dimensions of the channel drain body is cut from a waterproof membrane. Adhesive is applied to the flange, and the waterproof membrane is placed over the channel drain with the waterproof membrane hole positioned over the channel drain body. The waterproof membrane is then secured to the flange. The grate is then positioned within the body and tile is installed on the waterproof membrane about the grate.

In another aspect, a tile plug template that is positionable within the channel drain body may be provided. The hole through the subfloor and the backerboard, and the hole through the waterproof membrane could be dimensioned and cut with the tile plug template. In still another aspect, the tile plug template could be positioned within the channel drain body prior to placing the waterproof membrane over the channel drain with the waterproof membrane hole positioned over the channel drain body, and removed after securing the waterproof membrane to the flange.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing features of the invention will be apparent from the following Detailed Description of the Invention, taken in connection with the accompanying drawings, in which:

FIG. 1 is a cross-sectional view of a prior art floor drain assembly;

FIG. 2 is a perspective view of a channel drain assembly of the present disclosure;

FIG. 3 is an exploded perspective view of the channel drain assembly of FIG. 2;

FIG. 4 is a top view of the floor drain assembly of FIG. 2;

FIG. 5 is a perspective view of the channel drain assembly of FIG. 2 including floor elements;

FIG. 6 is a cross-sectional view of the floor drain assembly of FIG. 5 taken along line 6-6;

FIG. 7 is an alternate embodiment of the channel drain assembly of the present disclosure;

FIG. 8 is a perspective view showing installation of a channel drain of the present disclosure; and

FIG. 9 is a perspective view showing installation of the channel drain assembly of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a channel drain having an integral weep path.

FIG. 2 is a perspective view of a channel drain assembly 100 having an integral weep path, and FIG. 3 is an exploded perspective view of the channel drain assembly of FIG. 2. The channel drain assembly 100 includes a channel drain 102 including a drain body 104, a membrane flange 106, and a drain pipe 108. The drain body 104 includes one or more sidewalls 105 a, and a bottom wall 105 b. A drain pipe 108 extends from the bottom wall 105 of the drain body 104, and allows water to flow out from the channel drain 102. The flange 106 extends outwardly from an upper periphery of the drain body 104. The channel drain assembly 100 further includes a grate 110 that includes one or more grate sidewalls 112, a top wall 113, a plurality of stand-offs 114, and a primary drain path 116 that is defined by a plurality of removed sections extending through the top wall 113. The grate 110 is dimensioned similar to that of the drain body 104, such that the grate 110 can be placed on the channel drain 102 with the stand-offs 114 extending into the drain body 104.

FIG. 4 is a top view of the floor drain assembly of FIG. 2. When the grate 110 is positioned on the channel drain 102 a small gap, or integral weep path, 118 is formed between one or more of the grate sidewalls 112 and one or more of the sidewalls 105 a of the drain body 104. The integral weep path 118 permits fluid that does not flow through the primary drain path 116, e.g., through the grate 110, to flow along a secondary drain path to the drain body 104, e.g., along the flange 106 and through the integral weep path 118. Accordingly, the channel drain assembly 100 includes two integral drain paths by way of the primary drain path 116 and the weep path 118.

FIG. 5 is a perspective view of the channel drain assembly of FIG. 2 showing floor elements. When installed in a floor, the channel drain assembly 100 requires a plurality of floor elements to be installed along with the channel drain assembly 100. These floor elements include a waterproof membrane 120, a tile adhesive 122, and tile 124. The waterproof membrane 120 is positioned and installed on to the top of, and extending outwardly from, the membrane flange 106. The waterproof membrane 120 extends about the entire periphery of the flange 106, and can extend out from the membrane flange 106 varying distances dependent upon an installer's desires. The waterproof membrane 120 provides a layer of waterproof protection such that fluid that does not drain through the primary drain path 116, e.g., through the grate 110, could flow along the waterproof membrane 120, through the integral weep path 118, into the drain body 104, and out the drain pipe 108. As mentioned previously, the distance that the waterproof membrane 120 extends from the channel drain assembly 100 could be based on the purpose of installation. For example, where the channel drain assembly 100 is being used for a multi-shower room, e.g., a fitness center communal shower area, the waterproof membrane 120 could extend several feet. However, on the other hand, if the channel drain assembly 100 is to be installed in a personal shower area then it could only extend a couple feet from the drain body 104. The tile adhesive 122 is placed on top of the waterproof membrane 120 for securing the floor tiles 124 in place. The tile adhesive 122 could be mastic or thinset mortar. The floor tiles 124 are installed on top of the tile adhesive, with each floor tile 124 bonded to one another with grout 126. In such an arrangement, the floor tiles 124 are bonded to the waterproof membrane 120 by the tile adhesive 122. The floor tiles 124 could be ceramic tiles, or any other tile that is known in the art. Generally, when installed, the floor tiles 124 will be at the same height as the top of the grate 110 such that a flat transition is created from the floor tiles 124 to the grate 110. In some embodiments, the floor tiles 124 adjacent the grate 110 could be secured to the grate 110 by grout 126.

FIG. 6 is a cross-sectional view of the floor drain assembly of FIG. 5 taken along line 6-6. The drain body 104 is generally installed in a floor that includes a backerboard 128 and a subfloor 130. As illustrated in FIG. 6, the drain body 104 is seated within the backerboard 128 and subfloor 130, such that the membrane flange 106 rests on the backerboard 128. The waterproof membrane 120 is installed over the backerboard 128 and the membrane flange 106. As can bee seen in FIG. 6, the weep path 118 is formed between the sidewalls 105 a of the channel drain 102 and the grate sidewalls 112. Thus, fluid can flow along the waterproof membrane 120, through the weep path 118, and into the drain body 104. The stand-offs 114 elevate the grate sidewalls 112 from the drain body 104 providing space for fluid to flow.

Additionally, the stand-offs 114 may elevate the grate 110 so that the top wall 113 is substantially co-planar with the floor tile 124. Furthermore, the floor tile 124 and the waterproof membrane 120 are installed at a slight incline so that fluid will flow into the first flow path 116 and the weep path 118, respectively, instead of pooling.

The drain body 104 could be constructed in various shapes. For example, the drain body 104 could be rectangular, as illustrated in FIGS. 2-6, circular, square, or any other geometric configuration known in the art. Similarly, the grate 110 would be of similar geometric configuration.

FIG. 7 is a perspective view of an alternate embodiment of the channel drain assembly of the present invention. The channel drain assembly 200 includes a channel drain 202 including a drain body 204, a membrane flange 206, and a drain pipe 208. The drain body 204 includes one or more sidewalls (not shown), a bottom wall 205, and a basin 207 extending from the bottom wall 205. A drain pipe 208 extends horizontally from the basin 207 and allows water to flow out from the channel drain 202. This arrangement permits fluid to flow out from the drain pipe 208 and generally parallel with a floor that the channel drain assembly 200 is installed in. The flange 206 extends outwardly from an upper periphery of the drain body 204. The channel drain assembly 200 further includes a grate 210 that includes one or more grate sidewalls 212, a top wall 213, a plurality of stand-offs (not shown), and a primary drain path 216 that is defined by a plurality of removed sections extending through the top wall 213. The grate 210 is dimensioned similar to that of the drain body 204, such that the grate 210 can be placed on the channel drain 202 with the stand-offs 214 extending into the drain body 204. The channel drain assembly 200 illustrated in FIG. 7 functions and is installed substantially similarly to the channel drain assembly 100 of FIGS. 2-6. Such functionality and installation need not be repeated.

FIG. 8 is a perspective view showing installation of a channel drain of the present disclosure, and FIG. 9 is a perspective view showing a channel drain of the present disclosure partially installed. To install the channel drain 102, an installation location is first selected. A subfloor 130 and backerboard 128 are installed at the installation location according to local codes. A cardboard tile plug 134, which is shaped to generally match the geometric shape of the drain body 104, is provided and used as a template to mark a rectangular cut-line on the backerboard 128. The cut-line should be sized slightly larger in width and length dimensions, e.g., ¼″, than the channel drain 102 to be installed. This extra space provides clearance for the channel drain 120. An installer then cuts a hole 132 in the backerboard 128 and the subfloor 130 according to the cut-line and template. The square hole 132 will act as a housing for the channel drain 102.

A bead of silicone caulking is applied to the underside of the membrane flange 106, and the channel drain 102 is then installed such that the drain body 104 is inserted into the hole 132 and the membrane flange 106 rests on and are bonded to the backerboard 128. An installer then cuts a piece of waterproof membrane 120 to a desired size and removes a portion at the center of the waterproof membrane 120 according to the cardboard tile plug template 134. This removed portion is sized to match the length and width of the drain body 104. An adhesive 136 is applied to the membrane flange 106. The cardboard tile plug 134 is then placed in the drain body 104 and the waterproof membrane 120 is placed over the channel drain 102, such that the cardboard tile plug 134 is positioned within the removed portion of the waterproof membrane 120. The waterproof membrane 120 is then pressed down and bonded with the membrane flange 106 by the adhesive 136. The waterproof membrane 120 could also be installed according to a manufacturer's instructions.

The tile adhesive 122, e.g., thinset mortar, is then applied to the waterproof membrane 120. Once the tile adhesive 122 is completely applied, the floor tiles 124 are installed on the tile adhesive 122. The floor tiles 124 may also be installed with grout 126 applied between the floor tiles 124. Subsequently, the tile plug 135 is then removed and the grate sidewalls 112 is placed into the channel drain 102 and could be bonded to the floor tiles 124 by grout 126.

Having thus described the invention in detail, it is to be understood that the foregoing description is not intended to limit the spirit or scope thereof. What is desired to be protected is set forth in the following claims. 

1. A channel drain assembly, comprising: a channel drain including a body having at least one sidewall and a bottom wall, a flange extending about a periphery of the body, and a drain pipe; and a grate positionable within the body and including at least one side wall, a top wall, and a plurality of stand-offs extending from the at least one side wall of the grate, the top wall having a plurality of apertures extending therethrough; wherein when the grate is positioned within the body a first flow path and a second flow path are formed that provide a path for fluid to flow into the channel drain and out the drain pipe, the first flow path being formed across the plurality of apertures, the second flow path being formed between the at least one side wall of the grate and the at least one sidewall of the channel drain body, and wherein when the grate is positioned within the body, the stand-offs extend below the flange and raise the at least one sidewall of the grate above the bottom wall of the channel drain.
 2. The channel drain assembly of claim 1, wherein the drain pipe extends from the bottom wall of the body.
 3. The channel drain assembly of claim 1, further comprising a basin extending from the bottom wall of the body, wherein the drain pipe extends from a side wall of the basin.
 4. (canceled)
 5. The channel drain assembly of claim 1, wherein the channel drain body and grate are rectangular in shape.
 6. The channel drain assembly of claim 1, wherein the channel drain body and grate are circular in shape.
 7. A method of installing a channel drain assembly, comprising: providing a channel drain including a body, a flange extending about a periphery of the body, and a drain pipe; providing a grate positionable within the body and including at least one side wall and a top wall, the top wall having a plurality of apertures extending therethrough; determining a location for installation; installing a subfloor at the installation location; installing a backerboard on top of the subfloor; cutting a hole through the subfloor and the backboard, the hole dimensioned slightly larger than the dimensions of the channel drain body; placing the channel drain body into the hole such that the flange rests on the backerboard; cutting a hole from a waterproof membrane, the hole dimensioned to match the dimensions of the channel drain body; applying adhesive to the flange; placing the waterproof membrane over the channel drain with the waterproof membrane hole positioned over the channel drain body; securing the waterproof membrane to the flange; positioning the grate within the body; and installing tile on the waterproof membrane and about the grate.
 8. The method of installing a channel drain assembly of claim 7, further comprising bonding the grate and the tile with grout.
 9. The method of installing a channel drain assembly of claim 7, further comprising providing a tile plug template that is positionable within the channel drain body.
 10. The method of installing a channel drain assembly of claim 9, wherein the hole through the subfloor and the backerboard is dimensioned and cut with the tile plug template.
 11. The method of installing a channel drain assembly of claim 9, wherein the hole through the waterproof membrane is dimensioned and cut with the tile plug template.
 12. The method of installing a channel drain assembly of claim 7, wherein the tile plug template is positioned within the channel drain body prior to the step of placing the waterproof membrane over the channel drain with the waterproof membrane hole positioned over the channel drain body, and removed after the step of securing the waterproof membrane to the flange.
 13. The channel drain assembly of claim 1, wherein the stand-offs are configured to raise the top wall of the grate above the flange of the channel drain.
 14. The channel drain assembly of claim 1, wherein the stand-offs are configured to raise the top wall of the grate so that the top wall is substantially co-planar with a floor tile when the chain drain assembly has been installed.
 15. The channel drain assembly of claim 1, wherein the flange of the channel drain extends from the body of the channel drain at an angle so as to direct fluid into the body.
 16. The channel drain assembly of claim 1, further comprising a waterproof membrane positioned above and extending from the flange of the channel drain.
 17. (canceled)
 18. (canceled)
 19. (canceled)
 20. (canceled)
 21. (canceled)
 22. (canceled)
 23. (canceled)
 24. (canceled)
 25. (canceled)
 26. (canceled)
 27. (canceled) 